Part 2

DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY (for 2GR-FSE): REASSEMBLY - Continued




13. ADJUST TOTAL PRELOAD






(a) Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
SST: 09229-55010
Total preload (at starting):
New bearing
1.54 to 2.96 N*m (1.57 to 30.2 kgf*cm, 13.6 to 26.2 in.*lbf)
Reused bearing
0.82 to 1.96 N*m (8.4 to 20.0 kgf*cm, 7.3 to 17.3 in.*lbf)
- If the measured preload is less than the specified value, replace the rear differential side gear shaft snap ring of the ring gear tooth surface side with a thicker one.
- If the preload is greater than the specified value, replace the rear differential side gear shaft snap ring of the ring gear tooth surface side with a thinner one.
HINT: When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the total preload will change by approximately 0.1 N*m (1 kgf*cm, 0.9 in.*lbf).





(b) Set a dial indicator to the end of the differential ring gear face.
(c) While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.
Backlash:
0.08 to 0.13 mm (0.0031 to 0.0051 in.)
NOTICE:
- If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both right and left side gear shaft snap rings equally.
- When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash will also change by approximately 0.02 mm (0.0008 in.).

(d) Recheck the total preload.
14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Component Tests and General Diagnostics

15. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING






(a) Install the SST to the rear differential carrier.
SST: 09571-50010






(b) Install a dial indicator to the rear differential carrier.
(c) Tighten the SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0.004 in.) clearance between the case bearing outer race and side gear shaft snap ring.
NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).
HINT:
- Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.
- Approximately 0.1 mm (0.004 in.) clearance between the case bearing outer race and the side gear shaft snap ring is sufficient for the washer to move slightly.





(d) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.
(e) Remove the dial indicator and loosen the SST bolt.
NOTE: Do not remove the SST.

16. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING






(a) Using SST and a hammer, create a clearance between the case bearing outer race on the ring gear and side gear shaft snap ring.
SST: 09608-32010
SST: 09950-70010
09951-07200
HINT: The clearance is not visible, but tapping the SST with a hammer 3 or 4 times should be enough.





(b) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.
17. REMOVE REAR DIFFERENTIAL CASE BEARING






(a) Tighten the SST bolt and push out the case bearing outer race on the ring gear back surface side.
SST: 09571-50010
NOTE: Do not drop the case bearing outer race.
- To use as a reference for installation, clearly write the installation positions of the rear differential case bearing (outer race) and the rear differential side gear shaft snap ring.
- Put identification marks on the case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.





(b) Remove the SST.
18. REMOVE REAR DIFFERENTIAL CASE BEARING






(a) Raise the ring gear side of the differential case slightly to remove the ring gear tooth side case bearing outer race.
- For reassembly, check the installation position of the case bearing outer race and the side gear shaft snap ring before removing the case bearing outer race. Write down the result.
- Put identification marks on the case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

19. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY






(a) Remove the rear differential case assembly.
NOTE: Do not damage the case bearing.

20. REMOVE REAR DRIVE PINION NUT






(a) Using SST to hold the flange, remove the drive pinion nut.
SST: 09229-55010
SST: 09330-00021
SST: 09950-30012
09955-03040
21. REMOVE REAR DRIVE PINION COMPANION FLANGE






(a) Using SST, remove the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
NOTE: Apply grease to the threads and tip of the SST center bolt before use.

22. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER






(a) Remove the differential drive pinion oil slinger.
23. REMOVE DIFFERENTIAL DRIVE PINION






(a) Using a press, remove the drive pinion from the differential carrier.
NOTE: Do not drop the drive pinion.

24. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING






(a) Remove the rear drive pinion front tapered roller bearing from the differential carrier.
25. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER






(a) Install a new drive pinion bearing spacer to the drive pinion.
HINT: The bearing spacer can be installed in either direction.

26. INSTALL DIFFERENTIAL DRIVE PINION






(a) Using SST and a press, install the differential drive pinion to the differential carrier.
SST: 09316-60011
09316-00011
09316-00041
SST: 09608-04031
27. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER






(a) Install the differential drive pinion oil slinger to the differential drive pinion.
28. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL






(a) Using SST and a hammer, install a new oil seal.
SST: 09316-60011
09316-00011
SST: 09710-30012
09710-04101
Oil seal installation depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)
(b) Apply MP grease to the oil seal lip.
29. INSTALL REAR DRIVE PINION COMPANION FLANGE






(a) Using SST, install the companion flange to the drive pinion.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09956-03060
09955-03040
NOTE: Apply grease to the threads and tip of the SST center bolt before use.

(b) Coat the threads of a new drive pinion nut with hypoid gear oil LSD.






(c) Use SST to hold the flange and torque the drive pinion nut.
SST: 09229-55010
SST: 09330-00021
SST: 09950-30012
09955-03040
Torque:
490 N*m (5,000 kgf*cm, 361 ft.*lbf) or less
- Do not tighten excessively, otherwise the threads will be stripped.
- Apply hypoid gear oil LSD to the threads of the nut and drive pinion.
HINT: Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), then tighten it further while observing the preload.

30. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY






(a) Insert the differential case from the ring gear tooth side.
NOTE: Do not damage the case bearing inner race or ring gear.

31. INSTALL REAR DIFFERENTIAL CASE BEARING






(a) Using SST and a hammer, install the ring gear tooth side case bearing outer race.
SST: 09608-32010
SST: 09950-70010
09951-07200
HINT: Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.





(b) Install SST to the differential carrier.
SST: 09571-50010
(c) Tighten the SST bolt until the SST disc lightly touches the case bearing outer race.






(d) Using SST and a hammer, install the ring gear back surface side case bearing outer race.
SST: 09608-32010
SST: 09950-70010
09951-07200
HINT: Tap in the case bearing outer race until it touches the case bearing inner race roller.

32. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING






(a) Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.
HINT: Use the side gear shaft snap ring installed when performing tooth contact adjustment.





(b) Set a dial indicator on the differential carrier.
(c) Tighten the SST bolt to alter the shape of the differential carrier by approximately 0.1mm (0.004 in.).
NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more that 0.2 mm (0.008 in.).





(d) Using snap ring pliers, install the side gear shaft snap ring on the ring gear tooth side.
HINT: Use the side gear shaft snap ring installed when performing tooth contact adjustment.





(e) Remove the dial indicator and tap the differential carrier on the ring gear tooth side using a plastic hammer to stabilize the case bearing.






(f) Remove the SST.
33. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD






(a) Using SST and a torque wrench, measure the preload.
SST: 09229-55010
Drive pinion preload (at starting):
New bearing
1.22 to 1.80 N*m (12.4 to 18.4 kgf*cm, 10.7 to 16.0 in.*lbf)
Reused bearing
0.50 to 0.80 N*m (5.0 to 8.2 kgf*cm, 4.4 to 7.1 in.*lbf)
- If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10°.
Torque:
490 N*m (5,000 kgf*cm, 361 ft.*lbf) or less
- If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped.
- If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.

34. INSPECT TOTAL PRELOAD Component Tests and General Diagnostics

35. INSPECT DIFFERENTIAL RING GEAR BACKLASH Component Tests and General Diagnostics

36. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION Component Tests and General Diagnostics

37. INSTALL REAR DRIVE PINION NUT






(a) Using SST and a hammer, stake the drive pinion nut.
SST: 09930-00010
38. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL






(a) Using SST and a hammer, install 2 new oil seals.
SST: 09223-15030
SST: 09950-70010
09951-07200
Oil seal installation depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)
(b) Apply MP grease to the oil seal lips.
39. INSTALL REAR DIFFERENTIAL DRAIN PLUG
(a) Using a hexagon wrench (10 mm), install the differential drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
40. REMOVE REAR DIFFERENTIAL CARRIER






(a) Remove the differential carrier from the overhaul attachment.
NOTE: Clean the fitting surface between the differential carrier and carrier cover.

41. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR






(a) Clean the seal packing attached on the differential carrier and carrier cover using a scraper and wire brush. Then remove the oil with white gasoline or equivalent.
NOTE: Do not scratch the sealing surface.

(b) Install the rear differential breather plug oil deflector to the rear differential carrier cover.
Torque: 7.0 Nm (70 kgf-cm, 62 ft-lbf)
42. INSTALL REAR DIFFERENTIAL CARRIER COVER






(a) Apply FIPG to the differential carrier at the position shown in the illustration.
FIPG:
08826-00090, THREE BOND 1281 or equivalent
- Apply the seal packing in a continuous bead, approximately 2 to 3 mm (0.08 to 0.12 in.) in diameter.
- Overlap the seal packing at least 10 mm at the beginning and the end of application.
- Install the differential carrier cover within 3 minutes of application.





(b) Install the differential carrier cover with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 35 ft-lbf)
NOTE: Do not fill the differential with oil or drive immediately after installing the differential carrier cover. Allow at least one hour for the sealant to dry before filling the differential. Avoid sudden acceleration and deceleration for at least 12 hours after installation of parts using FIPG sealant.

43. INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG






(a) Install the breather plug to the carrier cover.
Torque: 21 Nm (210 kgf-cm, 15 ft-lbf)